Consumable Container, Aerosol Generation Device and Refillable System Thereof, and Method Using the System

ABSTRACT

The present invention relates to a A consumable container for filling e-liquid into a heating cavity of an aerosol generation device, the aerosol generation device, a refillable aerosol generation system thereof and a method for using the refillable aerosol generation system are provided. More specifically, a consumable container for filling e-liquid into a heating cavity of an aerosol generation device; comprises includes a shell and the e-liquid, wherein the shell has a flexible wall.

TECHNICAL FIELD

The present invention is directed to electronic cigarettes; morespecifically, the present invention is directed to a consumablecontainer for filling e-liquid into a heating cavity of an aerosolgeneration device, the aerosol generation device, a refillable aerosolgeneration system thereof and a method for using the refillable aerosolgeneration system.

BACKGROUND

An aerosol generation device, or e-cigarette, is now a mainstreamproduct to simulate a traditional tobacco cigarette. There are manytypes of aerosol generation devices. The operation method of the aerosolgeneration device is to contain an aerosol generation carrier inside andto heat it. One type of the e-cigarette evaporates an e-liquid to formvapor which the user can inhale, so using such an e-cigarette is usuallycalled “vaping”. E-liquid is well-known as a type of mixture solutionused in vapor systems. E-liquid usually contains nicotine, and may alsocontain propylene glycol, glycerin, flavorings, additives, and/or otherkinds of vaping containments. There are different subtypes of this kindof e-cigarette, such as a closed tank system and an open tank system.While the closed tank system pairs pre-filled e-liquid capsules tospecific devices, the open tank system comprises a fixed heating chamberin the device, which allows users to refill the device with any e-liquidwithout the need of attaching another element thereon, giving themmaximum scope for personalization and individual control.

The refilling of the open tank system can be achieved by using specificcontainers. For example, WO 2013/060827 A1 relates to kits for supplyinga cartridge of an open-tank inhaler article with liquid tobacco extract.More specifically, spray or bottle types of kits are disclosed todeliver the liquid tobacco extract to the cartridge. In the spray typekit, a mixture of cut tobacco and propylene glycol is provided in thebottle through a spray nozzle. In the bottle type kits, the usersqueezes the deformable bottle, and drops of tobacco extract areabsorbed onto the cartridge. The kits are, however, complex in structureand have the problem of leakage while refilling.

WO 2017/093452 A1 provides a reservoir assembly and a refill bottlecooperated with the reservoir assembly to refill liquid thereinto. Therefill bottle has a neck or a nozzle. During refilling, insertion of theneck or nozzle of the refill bottle into the housing is adapted to anadapter or directly to the reservoir assembly. This opens the flow pathto enable refill liquid to flow from the neck or nozzle of the bottleinto the reservoir. However, this system needs to have a nozzle ormouthpiece with a size and shape costumed to fit the adapter, thereservoir assembly or refillable cartridge.

SUMMARY OF THE INVENTION

To solve some or all of the above problems, the present inventionprovides a consumable container for filling e-liquid into a heatingcavity of an aerosol generation device, the aerosol generation device, arefillable aerosol generation system thereof and a method for using therefillable aerosol generation system.

A 1st embodiment of the invention is directed to a consumable containerfor filling e-liquid into a heating cavity of an aerosol generationdevice, comprising a shell and the e-liquid, wherein the shell has aflexible wall.

With this arrangement of the consumable container, the consumablecontainer is easy to carry and does not need to be customized into ashape or structure that fits specific types of vaping devices. Itensures that there is no leakage during refilling the e-liquid since theflexible container can always at least partially fit in the container.

According to a ₂nd embodiment, in the 1st embodiment, the shell is madeof pierceable film.

According to a 3rd embodiment, in the 1st or 2nd embodiments, the shellhas an average thickness of at most 500 µm, preferably 250 µm, morepreferably 100 µm, even more preferably 50 µm, and most preferably 30µm, and/or of at least 5 µm, preferably at least 10 µm, more preferablyat least 20 µm, most preferably at least 30 µm.

According to a 4th embodiment, in any one of the preceding embodiments,the shell comprises or is made of natural organic material.

According to a 5th embodiment, in any one of the preceding embodiments,the shell comprises or is made of alginate.

The shell made of alginate is flexible, low cost, easy to produce, waterinsoluble, easy to obtain, stable, thin while not easy to break, capableof preventing e-liquid from permeating through, has no reaction withe-liquid so as to prevent changing flavor, and is eco-friendly.

According to a 6th embodiment, in any one of the preceding embodiments,the shell comprises alginate hydrogels.

With this arrangement, the advantageous properties including mechanicalstiffness, swelling, degradation brought by alginate hydrogels can makethe container maintain a high load and easy to be formed.

According to a 7th embodiment, in any one of the preceding embodiments,the shell comprises or is made of alginate cross-linked membranes, morepreferably, calcium alginate polymer networks (membranes), which iscrosslinked by applying a calcium rich ion solution.

According to an 8th embodiment, in any one of the preceding embodiments,the consumable container has a pillow, ball, or droplet shape.

According to a 9th embodiment, in any one of the preceding embodiments,the consumable container has a stick-like protrusion extended from theconsumable container.

With this arrangement, the consumable container can be compact, solidand contain a relatively large volume of e-liquid.

According to a 10th embodiment, in any one of the preceding embodiments,the container has a volume of at most 18 ml, preferably 16 ml, morepreferably 12 ml, even more preferably 10 ml and most preferably 8 ml,and/or at least 1 ml, preferably 2 ml, more preferably 4 ml, even morepreferably 6 ml, and most preferably 8 ml.

According to an 11th embodiment, in any one of the precedingembodiments, the e-liquid comprises vegetable glycerin, propyleneglycol, nicotine and/or other tobacco products.

A 12th embodiment of the invention is directed to an aerosol generationdevice for the use of a consumable container of any one of the precedingembodiments, comprising a cavity for heating the e-liquid comprised bythe consumable container and a needle for penetrating the shell of theconsumable container.

With this arrangement, the aerosol generation device is capable ofbreaking or piercing the shell of the consumable container easily.

According to a 13th embodiment, in the 12th embodiment, the needle isarranged inside the cavity.

With this arrangement, the aerosol generation device is more compact.

According to a 14th embodiment, in the 13th embodiment, the needle isconfigured with a guiding tube for guiding the e-liquid flow into thecavity.

With this arrangement of the aerosol generation device, the consumablecan flow more easily into the heating cavity, without leakage.

According to a 15th embodiment, in the 12th embodiment, the needle isarranged at a cover of the aerosol generation device or outside thecavity of the aerosol generation device.

A 16th embodiment of the invention is directed to a refillable aerosolgeneration system, comprising an aerosol generation device according toany one of the above embodiments, and a consumable container accordingto any one of the above embodiments.

According to a 17th embodiment, in the 16th embodiment, the consumablecontainer has a size such that it can be at least partially set into theheating cavity of the consumable substance.

An 18th embodiment of the invention is directed to a method for usingthe refillable system according to any one of the 15th to 17th aspects,the method comprising the following steps:

-   penetrating a shell of the consumable container by a needle of the    aerosol generation device,-   filling e-liquid from the consumable container into a heating cavity    of the aerosol generation device, and-   taking the shell of the consumable container out of the aerosol    generation device.

According to an 19th embodiment, in any one of the 1st to 10thembodiments, the shell is an alginate cross-linked membrane, preferably,the shell is formed by crosslinking alginate with calcium rich ionsolution, more preferably, the shell is formed into a membrane bycrosslinking calcium rich ion solution with a mixture of alginate and athickener.

With this method, the consumer can fill e-liquid with personalizedflavors into the heating cavity in a more clean and easy way, and theshell of the consumable container does not affect the taste of thevaping.

Preferred embodiments are now described, by way of example only, withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 : shows a schematic drawing of one embodiment of a consumablecontainer according to the invention;

FIGS. 2 a to 2 c : show schematic drawings of other embodiments of theconsumable container according to the invention;

FIG. 3 : shows a schematic drawing of a consumable container, a heatingcavity of an aerosol generation device and a needle (filter/adapter)unit in position before refilling according to the invention;

FIG. 4 : shows a flow chart of a method for using a refillable aerosolgeneration system according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention are described hereinafterand in conjunction with the accompanying drawings.

As used herein, the term “vaporizer system”, “inhaler” or “electroniccigarette” may include an electronic cigarette configured to deliver anaerosol to a user, including an aerosol for smoking. The illustratedembodiments of the vaporizer system in this invention are schematic andit is also possible to combine some of the parts to single units whichwill be apparent to a person skilled in the art, such as the powersupply unit, and electrical circuitry.

The present invention provides a consumable container for fillinge-liquid into a heating cavity of an aerosol generation device. Theconsumable, namely e-liquid, may be a tobacco product in the form of aliquid or semi-liquid. As a typical consumable for the e-cigarettes, andin particular a vaporizer device, e-liquid is a well-known mixturesolution which usually comprises nicotine, and it may also comprisecontainments such as propylene glycol, glycerin, nicotine, flavorings,additives, cut tobacco particles and/or the like.

FIG. 1 is a schematic diagram of the consumable container ₁. Theconsumable container 1 comprises a shell and the e-liquid. Theconsumable can be a capsule having a pillow shape with flexible walls,which are made of pierceable films. For the pierceability, the films aresubstantially thin, e.g. have an average thickness of at most 500 µm,preferably at most 250 µm, more preferably at most 100 µm, even morepreferably at most 50 µm, and most preferably at most 30 µm, and/or ofat least 5 µm, preferably at least 10 µm, more preferably at least 20µm, and most preferably at least 30 µm. The film can be made of anymaterial that is stable and able to secure the consumable container 1sot that it does not to break easily when being carried, while at thesame time, it can be pierced via a sharp object such as a needle. Theshell of the e-liquid is capable of preventing substantially all of thee-liquid from permeating through the substantially liquid-tight sealedshell.

Preferably, the material of the shell is a natural organic material, andmore preferably, alginate/seaweed. More specifically, the shall isformed by a membrane which is made of alginate hydrogels. The strengthof the alginate hydrogels can advantageously be sufficiently high tomaintain the physical integrity under pressure so as to not break.Except for the above benefits, the membrane made of alginate (hydrogels)is flexible, low cost, water insoluble, easy to source and eco-friendly.It is also easy to produce, without a demand of a specific manufacturingenvironment— normal conditions like room temperature and atmosphericpressure are sufficient. In preferred embodiment, the shell comprises oris made of alginate cross-linked membranes, more preferably, calciumalginate polymer networks (membranes), which is crosslinked by applyinga calcium rich ion solution so as to create a water insoluble membrane(shell). During manufacturing, a solution of alginate and a thickenerare blended and extruded through an appropriately shaped die to form amembrane; the membrane is applied with by spraying or submerging in abath of a calcium rich ion solution to crosslink the membrane and createa water insoluble membrane; the water insoluble membrane is filled withthe e-liquid product; and the membrane is sealed around the e-liquidproduct, so as to encapsulate the e-liquid product therein. The alginatecross-linked membrane, i.e. the shell which forms the consumablecontainer ₁, has a better water insoluble performance and an increasedmechanical strength.

Specifically, the calcium ion solution has a concentration of,preferably, 1-10 wt%, more preferably, 1-5 wt%, most preferably 1-2.5wt%, which substantially avoids affecting the taste of the e-liquid. Thethickener is preferably xanthan or cellulose gum. More specifically, insome embodiments, the consumable container 1 is formed into a membraneform by blending the alginate (preferably the concentration thereof inthe solution is 1-10 wt%) and the thickener. The membrane 1 is thencrosslinked with the calcium rich ion solution. Preferably, theconcentration of calcium in the mixture, which is the blended comprisingthe alginate and thickener which is extruded to form the membrane, is0.02% or less. By pinching and cutting the membrane and forming theconsumable substance into a shape, such as a droplet form, theconsumable container 1 is eventually formed by covering the consumablesubstance with the membrane, and then encapsulating the consumablesubstance with the membrane by a pinching machine or a glue. In order tofurther improve the mechanical strength, the encapsulated consumablecontainer 1 is heated at 40° C. or higher, which may result in a densermatrix, appearance and reduced permeability once the consumablecontainer 1 is formed, and this step does affect the e-liquidencapsulated within.

In preferred embodiments, the e-liquid comprises vegetable glycerin,propylene glycol, and nicotine. It may comprise other tobacco productsin other embodiments. The e-liquid is preferably not fully filled intothe capsule, as shown by the dotted lines in FIG. 1 , during theproduction of the consumable container 1. This can make the refilling ofthe consumable easier to control since the e-liquid therein is notlikely to burst out once the film is penetrated by a needle. The gas inthe capsule can be air, and preferably a chemically inactive gas, suchas nitrogen. Alternatively, the consumable container 1 can be completelyfilled with the e-liquid.

The consumable container 1 may have any other shape than the pillowshape, as long as the consumable container 1 has a shape and size thatcan be at least partially set into a heating cavity of an aerosolgeneration device. The volume of the container should be at most 18 cm³.For example, the consumable container 1 can have a shape of a ball (notshown), droplet (FIG. 2 a ), a tetrahedron (FIG. 2 b ), or any shape,preferably a pillow shape, with a stick-like protrusion extended fromthe consumable container 1 (FIG. 2 c ).

The container may have a volume that can partially fill or fully fillthe heating cavity of the aerosol generation device. For example, it mayhave a volume of at most 18 ml as mentioned above, preferably at most 16ml, more preferably at most 12 ml, even more preferably at most 10 mland most preferably at most 8 ml, and/or of at least 1 ml, preferably atleast 2 ml, more preferably at least 4 ml, even more preferably at least6 ml, and most preferably at most 8 ml.

One embodiment of the manufacturing of the consumable container 1 isdescribed in EP 3 601 061 A1 to NOTPLA.

The aerosol generation device for use of the consumable container 1 maybe similar to or based on any known vapor device, preferably open-tanksystem e-cigarettes, such as the ones in WO 2013/060827 A1 or WO2017/093452 A1. It may have a disassemble heating cavity or a fixedheating cavity with an opening covered by a cover. While a closed-systemvaping device has a closed vaping chamber, and the entire unitcomprising the closed vaping chamber is to be replaced after theconsumable therein runs out, an open-tank vaping device has an opentank/vaping chamber/heating chamber/cavity which is refillable from aconsumable container 1.

The aerosol generation device further comprises a needle unit packedwith the consumable container ₁, or preferably the aerosol generationdevice. More preferably, the needle unit is attached with the aerosolgeneration device through a connector such as a magnetic, sliding memberor the like. Even more preferably, the needle unit is fixedly comprisedin the aerosol generation device. Most preferably, the needle unit isarranged inside the cavity. In some embodiments, the needle unit isconfigured with a guiding tube for guiding the e-liquid flow into thecavity; more specifically, the needle unit is a tube- or funnel-shapemember with a sharp needle-like point. In some embodiments, the cavityhas an opening and a cover covering the opening, and the needle isarranged on the cover. In other embodiments, the needle unit is attachedto the outside of the vaping device through a connector by a slidingmechanism, magnetic, joining socket or any other type of connectingmethods.

FIG. 3 shows a consumable container ₁, a heating cavity/vaping chamberpart 3 of an aerosol generation device (not shown), based on the vapingdevice disclosed in WO 2017/093452, and a needle unit 2, which are aboutto connect before the process of refilling e-liquid into the heatingcavity 3. The needle unit 2 in this embodiment is an adapter with afunnel having a needle shape at one end and a filter at another end. Thefilter can filter out the substance or the impurities inside thee-liquid if the e-liquid is a semi-liquid. The adapter can be attachedbetween the main body and the heating chamber while vaping or is to betaken out after the refilling and before the vaping of the aerosolgeneration device. Alternatively, the needle unit 2 may be without afilter, if the e-liquid is a pure liquid. In some embodiments, theneedle is fixed inside the heating cavity 3.

FIG. 3 illustrates parts of the refilling system before use. As shown inFIG. 3 and FIG. 4 , for refilling the consumable container 1, theheating cavity 3 is dissembled from the main body (not shown) of theaerosol generation device. The needle adapter needs to be attached onthe heating cavity 3 along an insertion direction I. The consumablecontainer 1 is placed on the needle adapter, and a shell of theconsumable container 1 is penetrated by the needle end of the needleunit 2 along the insertion direction I (while placing the systemhorizontally or vertically) (S101). The consumable container 1 can besqueezed by hand so as to increase the pressure on the consumablecontainer 1 (the consumable may also flow into the cavity 3 throughother force such as gravity). Trough the funnel of the needle unit 2,the e-liquid from the consumable container 1 is filled into a heatingcavity 3 of the aerosol generation device (S102). After finishing therefilling, the shell of the consumable container 1 or the emptyconsumable container 1 needs to be taken out of the aerosol generationdevice (S103). For consuming the e-liquid, the needle adapter isdetached from the heating cavity 3, and the heating cavity 3 isre-assembled onto the main body of the aerosol generation device. Withthe refilled heating cavity, the aerosol generation device is switchedon for consuming and vaping the consumable (S104).

1. A consumable container for filling e-liquid into a heating cavity ofan aerosol generation device, comprising a shell and an e-liquid,wherein the shell has a flexible wall.
 2. The consumable containeraccording to claim 1, wherein the shell is made of pierceable film. 3.The consumable container according to claims 1, wherein the shell has anaverage thickness of at most 500 µm and of at least 5 µm.
 4. Theconsumable container according to claim 1, wherein the shell comprisesor is made of alginate.
 5. The consumable container according to claim1, having a pillow, ball, or droplet shape.
 6. The consumable containeraccording to claim 1, wherein the container has a volume of at most 18ml, and at least 1 ml.
 7. The consumable container according to claim 1,wherein the e-liquid comprises vegetable glycerin, propylene glycol,nicotine and/or other tobacco products.
 8. An aerosol generation devicefor use with a consumable container, comprising a cavity for heating ane-liquid in the consumable container and a needle for penetrating ashell of the consumable container.
 9. The aerosol generation deviceaccording to claim 8, wherein the needle is arranged inside the cavity.10. The aerosol generation device according to claim 9, wherein theneedle includes a guiding tube for guiding flow of the e-liquid into thecavity.
 11. The aerosol generation device according to claim 8, whereinthe needle is arranged at a cover of the aerosol generation device oroutside the cavity of the aerosol generation device.
 12. A refillableaerosol generation system, comprising the aerosol generation deviceaccording to claim 8, and a consumable container for filling e-liquidinto a heating cavity of the aerosol generation device, the consumablecontainer comprising a shell and an e-liquid, wherein the shell has aflexible wall.
 13. The refillable aerosol generation system according toclaim 12, wherein the consumable container has a size such that theconsumable container is configured to be at least partially set into theheating cavity of the aerosol generation device.
 14. A method for usinga refillable aerosol generation system, wherein the method comprisessteps of: penetrating a shell of a consumable container by a needle ofan aerosol generation device, filling e-liquid from the consumablecontainer into a heating cavity of the aerosol generation device, andtaking the shell of the consumable container out of the aerosolgeneration device.
 15. The method for using a refillable aerosolgeneration system according to claim 14, wherein in the shell-takingstep, the shell is taken out of the aerosol generation device afterfinishing the refilling step and before a step of consuming of thee-liquid.